Transfer Case Chain

This procedure covers the removal and replacement of the transfer case chain in the NV241 or NV271 transfer case used in 1994-2007 Dodge Ram 2500 4WD vehicles with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Transfer case chain × 1 — Use OEM Mopar or equivalent HD chain for NV241/NV271
• Transfer case gasket/seal kit × 1 — Use OEM specification
• RTV silicone gasket maker × 1 — Mopar or high-temp RTV
• Front and rear output shaft seals × 2 — Included in seal kit or purchase separately
• Input shaft seal × 1 — Included in seal kit
• Shift fork pads (if worn) × 1 — Inspect during disassembly

Fluids

• Mopar ATF+4 — 5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable to prevent accidental starter engagement
3. Raise vehicle and support securely on jack stands under frame rails
4. Remove skid plates if equipped to access transfer case
5. Allow transfer case to cool if vehicle was recently driven
6. Place drain pan under transfer case drain plug location
7. Mark front and rear driveshaft positions relative to yokes for proper reinstallation phasing

Procedure

1. 1

   Drain transfer case fluid
   Locate and remove the drain plug on the bottom of the transfer case. Allow all transfer case fluid to drain completely into the drain pan. Note: 1994-1998 models used Dexron/Mercon-type ATF while 1999-2007 models use Mopar ATF+4 — verify the correct fluid specification for your model year. If no drain plug is present on your model, fluid will drain when the case is split. Clean the drain plug and inspect the magnetic tip for excessive metal debris which may indicate internal damage.
2. 2

   Disconnect driveshafts
   Remove the front driveshaft by unbolting the CV joint bolts at the front axle and the u-joint straps or bolts at the transfer case output yoke. Support the driveshaft and remove completely. Repeat for the rear driveshaft, removing the u-joint straps at both the transfer case and rear differential. Cap or tape the output yokes to prevent dirt entry.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)

   Driveshaft Bolts75 Nm (55 lb-ft)
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect the transfer case shift linkage rod or cable from the range lever. On electronic shift models, disconnect the shift motor electrical connector and vehicle speed sensor connector. Remove any vent hose from the top of the transfer case. Label all connections for reinstallation.
4. 4

   Support and remove transfer case
   Position a transmission jack or transfer case support under the transfer case. Remove the mounting bolts securing the transfer case to the transmission adapter. Carefully slide the transfer case rearward to disengage the input shaft from the transmission output shaft. Lower the transfer case and remove from under the vehicle. Place on a clean workbench.
   ⚠Transfer case is heavy and awkward. Ensure jack is centered and secure before removing mounting bolts. Have an assistant help guide the unit during removal.
5. 5

   Remove transfer case rear cover
   With the transfer case on the bench, remove all rear cover bolts. Carefully separate the rear cover from the main case using a dead blow hammer or soft mallet. Do not pry aggressively as this may damage sealing surfaces. Note the location of any dowel pins. Remove the cover and set aside.
6. 6

   Remove shift rail and forks
   Remove the shift rail retaining bolt or snap ring. Carefully slide out the shift rail while noting the position and orientation of shift forks. Remove the mode fork, range fork, and any associated springs or detent mechanisms. Inspect shift fork pads for wear and replace if necessary. Keep all components organized for reassembly.
7. 7

   Remove chain and sprockets
   Using snap ring pliers, remove the snap rings retaining the driven sprocket on the rear output shaft. Slide the driven sprocket forward and lift the chain off both sprockets. Remove the chain from the case. Remove the drive sprocket from the input shaft if it is not press-fit. Inspect both sprockets for wear, scoring, or damaged teeth. Replace sprockets if wear is evident.
   ℹ️Note the orientation of the chain. Some chains have directional markings that must be observed during installation.
8. 8

   Clean and inspect internal components
   Thoroughly clean all internal case surfaces, shafts, and bearings with solvent and compressed air. Inspect the mainshaft, rear output shaft, and front output shaft bearings for roughness or play. Check the planetary gear set (if equipped) for damage. Inspect the case halves for cracks or porosity. Replace any worn or damaged components before proceeding.
9. 9

   Install new chain and sprockets
   Install the drive sprocket onto the input shaft if it was removed, ensuring proper seating and orientation. Place the new chain around both the drive and driven sprockets. Install the driven sprocket onto the rear output shaft, ensuring the chain is properly seated in both sprocket teeth. Install the snap rings to secure the driven sprocket. Verify the chain is properly seated on both sprockets and replace the chain if the old one showed excessive stretch or the sprocket teeth showed wear. Consult the factory service manual for wear specifications.
   ℹ️Ensure chain is not twisted and that it engages all teeth properly on both sprockets before securing.
10. 10

    Reinstall shift forks and rail
    Reinstall the range fork and mode fork in their correct positions, engaging them with their respective clutch sleeves and hubs. Insert the shift rail through the forks, ensuring detent balls and springs are properly positioned. Secure the shift rail with the retaining bolt or snap ring. Verify forks move freely through their full range of motion without binding.
11. 11

    Prepare and install rear cover
    Thoroughly clean the rear cover and case mating surfaces with a gasket scraper and solvent. Remove all old gasket material and RTV. Apply a thin, continuous bead of RTV silicone sealant to the rear cover mating surface or install the new gasket per manufacturer instructions. Align the rear cover with any dowel pins and carefully install it onto the case. Install and hand-tighten all cover bolts, then torque in a criss-cross pattern.
    ℹ️Allow RTV to set for the manufacturer-recommended time before filling with fluid if using RTV instead of a gasket.
12. 12

    Reinstall transfer case to vehicle
    Position the transfer case on the transmission jack and raise into position under the vehicle. Align the input shaft with the transmission output shaft splines and carefully slide the transfer case forward. Install the mounting bolts and torque to specification. Remove the support jack once all bolts are secure.
    ⚠Ensure input shaft is properly aligned with transmission output shaft before forcing the case forward. Misalignment can damage splines.
13. 13

    Reconnect driveshafts
    Install the rear driveshaft first, aligning the marks made during disassembly to maintain proper phasing. Install u-joint straps or bolts and torque to specification. Install the front driveshaft, connecting the CV joint to the front axle and the yoke to the transfer case output. Torque all fasteners to specification.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    Driveshaft Bolts75 Nm (55 lb-ft)
14. 14

    Reconnect linkage, electrical, and fill with fluid
    Reconnect the shift linkage to the range lever, ensuring proper adjustment. Reconnect all electrical connectors and the vent hose. Remove the fill plug on the side of the transfer case and fill with the correct transfer case fluid (approximately 2 quarts) until fluid reaches the bottom of the fill hole. Verify exact capacity and fluid type for your model year. Reinstall the fill plug. Reinstall skid plates if equipped.
15. 15

    Test transfer case operation
    Lower the vehicle from jack stands. Reconnect the negative battery cable. Start the engine and allow it to reach operating temperature. With the vehicle stationary and brake applied, shift the transfer case through 2H, 4H, and N. Shift into 4L per the owner's manual procedure (typically with transmission in neutral and vehicle stopped or rolling slowly). Verify smooth engagement in all ranges. Test drive the vehicle in both 2WD and 4WD modes, listening for abnormal noises or vibrations. Check for fluid leaks at the rear cover and output shaft seals.
    ⚠Only engage 4WD on surfaces with adequate traction. Do not operate in 4WD on dry pavement as this can damage the drivetrain.

Reassembly

1. Reassembly is included in the main steps as this procedure requires complete disassembly and reassembly of the transfer case
2. Ensure all fasteners are torqued to specification in the proper sequence
3. Verify proper chain tension and sprocket alignment before sealing the case
4. Allow adequate time for RTV sealant to cure before filling with fluid if RTV was used

Verification

• Check for fluid leaks at the rear cover, output shaft seals, and drain/fill plugs after initial test drive
• Verify smooth shifting between all transfer case ranges with no grinding or hesitation
• Confirm proper 4WD engagement by observing front axle rotation and feel during operation
• Listen for abnormal chain noise or whining during operation in all ranges
• Verify fluid level is correct at operating temperature and top off if necessary
• Test vehicle on a safe surface to ensure proper power delivery to all wheels in 4WD mode

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